CONCRETE TRENDS 2021 ISSUE 4 by dmgeventsafrica

CONCRETE trends Issue 4 2021

The voice of the industry

Twinstar Precast – The Custom Concrete Puzzle Solution Strategies for building 2022 www.concretetrends.co.za

Concrete bridges the housing gap

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Creating Concrete Possibilities

CONCRETE trends Issue 4 2021

COVER

The voice of the industry

TwinsTar PrecasT – The cusTom concreTe Puzzle soluTion strAtegies for building 2022

ConCrete bridges the housing gap

Admixtures, sealants and screeds

www.concretetrends.co.za

CONTENTS

From specialised structures to weight-bearing delivery areas. From shopping malls, housing complexes, hospitals and cultural centres, to windfarms, roads, bridges, airports and bike racks, Twinstar Precast is uniquely positioned to cater for an extremely diverse range of industries.

Association trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 7 Cover Story . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Twinstar Precast – The custom concrete puzzle solution

Event trends

The Big 5 Construct Southern Africa 2022 . . . . . . . . . . . . . . . . . . . . . .

Industry trends

Cement paves the way to a brighter future . Advanced concrete technology training . . . Heavy duty sealants . . . . . . . . . . . . . . .

Innovation trends

. . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . 17

Reduce water and add a step to sustainable concrete . . . . . . . . . . . .

Project trends

Suspended acceleration – precast slabs . . . . . . The right mix of concrete for affordable housing .

Contracting trends

The new road to outcomes and performance .

Strategic trends

. . . . . . . . . . . . . 23 . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . 28

31 32 33 Strategic trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Aim to thrive, not survive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . New strategies for the business of building . . . . . . . . . . . . . . . . . . . . . Acquisitions driven by sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . Aim to thrive, not survive

Sector trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 The right mix of concrete for affordable housing

Product trends Speed for screed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Global trends Illuminating South Africa’s global opportunities . . . . . . . . . . . . . . 36

vice president: Devi Paulsen-Abbott email: DeviPaulsen@dmgevents.com Publishing Editor: Eamonn Ryan email: EamonnRyan@dmgevents.com T: +27 21 700 5608 M: +27 82 560 8718 PROJECT MANAGER: Tracy-Lee Behr email: TracyLeeBehr@dmgevents.com T: +27 21 700 5512 M: +27 73 367 9647

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Endorsed by industry:

ISSN 1560-2710

dmgevents and the editorial team accepts no responsibility for any opinions or statements in this publication. Consequently no person connected with the publication of this journal will be liable for any loss or damage sustained by any reader as a result of action following any statements or opinions expressed herein.

Editor’s comment

Expect the unexpected

ithout too much fanfare, a project in Malawi saw an entire school built using 3D printing. This has led to a new housing project in Kenya – billed as Africa’s largest 3D printed affordable housing project. The joint venture behind this project 14Tress, with finance partner, CDC Group. It may surprise some to Nicholas McDiarmid learn that leading partner, and developer of the 3D printing technology is none other than Holcim. The advances Holcim have made from being a leading producer of concrete and cement – with carbon intensity that goes with it – to becoming a zero-net carbon entity is actually quite astonishing. And like most workable solutions to the massive environmental, social and economic challenges of our times, it all comes down the fourth industrial revolution (4IR). The exponential potentials held in these two projects could well contain the foundation of a new prosperity for Africa, and the rest of the world. Using 3D printing with low-carbon concrete, intelligent design and an integration of innovations at every level of the process, 14Trees demonstrates some key concepts that apply to us all. But the good news for our concrete sector is that the path forward is very clear.

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Every part of South Africa’s the concrete value chain is critical to realising the huge potential of not just construction, but of a new era of integration, innovation and combination of technologies with materials, with processes and intelligent design. It is time for me to thank everyone in our concrete community who has made my time as editor of this wonderful magazine and website so rewarding, so enlightening and so fulfilling. The generosity of time, knowledge, advice and engagement of so many of you is a continual source of inspiration and optimism. Just as I know that Concrete Trends’ new editor, Eamonn Ryan (eamonnryan@dmgevents.com) will deliver everything you need to explore this exciting new world of concrete in the 4IR, I know that you will give him the same inspiration and optimism with which I say farewell. Have a wonderful, safe and rejuEamonn Ryan venating holiday break. And if we can expect anything for 2022, let it be unexpected advantages coming from the strength we all been quietly building. n Nicholas McDiarmid, Publishing Editor

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Association trends

MBA North partnership to bring affordable health & safety resources to SMEs

he Master Builders Association North (MBA North) has partnered with SHEQ Warehouse to help the regional construction sector access comprehensive health & safety resources at an affordable price. Boitumelo Thipe, MBA North Marketing and Business Development Manager says the partnership aims to create a comBoitumelo Thipe prehensive SHEQ Resource Centre for companies in the construction environment, to help them achieve Occupational Health & Safety compliance at affordable pricing. The emphasis will be on assisting the start-ups, Micro and SMME companies obtain access into the work market. Thipe notes that start-ups, micro and small businesses are often challenged in securing work due to the high standards, complexity and the costs of compiling and submitting a safety file. “Many small companies find that the high cost of having to send their staff for continuous medicals as well as multiple health and safety training courses, even before they are able to submit a quotation or tender, hampers their ability to access work,” she says. In line with MBA North’s ongoing efforts to support the construction industry in the face of economic challenges and the threat of Covid-19, the new partnership will give MBA North members access to a resource centre where they can obtain all the required high-quality documentation and resources, as well as support and assistance from MBA North’s Safety Specialist services. MBA North members now have access to all SHEQ Warehouse’s ISO 9001, ISO 14001, and ISO 45001 documentation, at

Concrete Trends Issue 4 2021

affordable pricing. In addition, SHEQ Warehouse’s ISO 45001, ISO 14001 and ISO 9001 Implementation specialists are at members’ disposal to assist them with the full ISO implementation and ISO Certification preparedness, first on-site or digital platform consultation free of charge. SHEQ Warehouse’s unique quality documentation includes comprehensive HSE Safety systems, various safety Files, safety packs and the company’s tried and tested Sub-Contractor Vetting System. SHEQ Warehouse (Pty) Ltd, a leading provider of SHEQ/ ISO resources, and ISO 9001, ISO 14001, and ISO 45001 implementation specialists, have been providing Health and Safety resources to the construction industry for over a decade, says SHEQ Warehouse CEO Neville Dick, a Health and Safety specialist and ISO 45001(SABS) Lead Auditor. Neville has also announced that over the next 7 – 14 days, comprehensive PowerPoint Safety Training presentations will be made available on the SHEQ Warehouse website, www.sheqwarehouse.co.za, consisting of all the relevant training required within the safety industry. This will assist safety officers to give comprehensive inhouse training where the industry allows such training. Training such as Legal Liabilities, Construction Managers & Supervisor, SHE Reps, Company inductions, Site inductions, HIRA, Incident Reporting & Investigation, COID, Working at Heights – Ladders, etc, to mention just a few of the training presentations that will be available. Over and above all of this, SHEQ Warehouse’s Digital Reporting system is also in the advanced stages of development, which will allow contractors and safety personnel to perform company inspections, site inspections, incident reporting, non-conformance reporting and monitoring and the creating and updating of risk assessments, all in the palm of their hands. n

Association trends

Surface mines dig deep to ensure supply

urface mines and quarries that are members of industry association, ASPASA, have committed to support efforts of the construction sector to rebuild the industry and reverse the effects of ongoing Covid-19 lockdowns. While the industry has been heavily affected by mine closures and restrictions as a result of Covid-19, it has committed to Nico Pienaar of ASPASA work hard to ensure sufficient building material supplies for contracts and to maintain pricing that is fair and sustainable for the industry. “ASPASA members are focussed on the longer-term goal of rebuilding the construction industry rather than profiteering from the material shortages. The pandemic will be with us for an extended time and it is our opinion that we have to get back to business as usual as possible,” says ASPASA director, Nico Pienaar. He continues that building materials are crucial to ensuring a reliable construction industry and support the efforts of the country to rebuild infrastructure damaged in the recent riots. During lockdown the industry faced challenges that related mainly to matters such as site closures, reductions in productivity and increased costs of compliance. However, this has changed with the evolving needs of the industry. Nico suggests that the largest factors hampering the supply of materials at present are: • Rapidly rising costs of most goods and services • Container availability and transportation challenges • A shortage of global raw materials • Insufficient product testing capacity as a result of ramp up • Use of illegal minerals on sites • Allowing Mafia-style businesses to take hold • Corruption • Using unnecessary borrow-pits • Not buying from reliable suppliers “As a result, ASPASA strongly urges those responsible for developing, agreeing, and managing contracts, to consider adopting provisions in their contracts and ensure that we have an honest and trustworthy industry. In addition, the contractual challenges created by lack of product availability and inability to access approved products are likely to mean design changes are necessary. “We therefore encourage a collaborative approach to be taken to managing these risks and we invite all stakeholders in the construction industry to contact our members and find ways of ensuring sufficient supply for current and future contracts. During these tough times we also encourage construction companies to use legal and reliable suppliers who are ASPASA members,” Nico concludes. n ASPASA, Nico Pienaar Tel: (011) 791 3327, Fax: 086 647 8034 Email: nico@aspasa.co.za, Web: www.aspasa.co.za

Concrete Trends Issue 4 2021

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Association trends

International enrolment for school of concrete technology training

here is ongoing international, as well as strong rural local interest in the online training by Cement and Concrete South Africa’s School of Concrete Technology (SCT), the oldest and largest provider of concrete technology education in South Africa which has for decades offered a wide range of acclaimed courses for all levels of competency. SCT, to comply with Covid-19 restrictions, currently offers a diverse selection of online concrete training courses tailored specifically to the needs of the concrete industry and hopes to again include live classes next year if pandemic conditions and restrictions allow. Since going online, students have enrolled for the SCT’s more advanced courses from diverse global areas including Uganda, Kenya, New Zealand and the United Arab Emirates, says John Roxburgh, senior lecturer at the School. “Staff of South African mines in remote areas have also made extensive use of the SCT30 ‘Concrete Technology’ course in preparation for their engineers’ mining ‘tickets’ of competency. For our more basic brick- and block-making courses, enrolments have come from distant rural areas such as Mthatha and Port St Johns in the Eastern Cape; Mkhuze, Msinga and Mvoti in KZN, as well as Giyani, Steelpoort, Phalaborwa and the Venda region in Limpopo province, to name just a few places,” Roxburgh states. The School’s 2022 Training Programme is scheduled for release soon but currently it offers more than 15 concrete training courses, three of which are internationally recognised, including the highly sought-after and internationally-

Concrete Trends Issue 4 2021

Students from diverse corners of the world have in recent months enrolled for School of Concrete Technology online training, says John Roxburgh, senior lecturer at the School.

recognised Advanced Concrete Technology (ACT) diploma. In addition, SCT offers special concrete technology courses tailormade for specific companies’ needs. The School’s team of trainers/lecturers can formulate courses to address a full range of skills training a company may need to add more creative strategic thinking and expertise to its ranks. “The SCT has structured a progression of course levels that will allow prospective students to join at a level that matches their personal competency. There can be no short cuts to becoming a good concrete technology practitioner and the School has all the educational requirements to help trainees meet their specific goals,” he states. Successful students for all SCTs courses receive certificates of attendance/competence and Continuing Professional Development (CPD) points are awarded on selected courses. For further information, phone 011 3150300 or email rennisha.sewnarain@cemcon-sa.org.za or visit www.cemconsa.org.za. n

The School of Concrete Technology has had enrolments from the United Arab Emirates for its advanced training courses. Pictured: a Dubai building site

Association trends

Danchi Group takes centre stage at Eskom’s Business Investment Competition

ased in Gauteng, Danchi Group manufactures steel components for the automotive and rail transport industries, including bushings, spacers, pins, pivots, and steel fabricated products such as columns, skips, pallets, scaffolding, sheeting, conveyor structures and shafts. They also refurbish steel components for their clients. “We identified a niche where we could merge the conventional way of fabrication with innovative product design to offer our clients cutting-edge solutions,” said Rachael Gaffane, Director at the Danchi Group. “I am passionate about making a change in this industry which has been very traditional and conventional. I want to introduce a youthful and innovative approach to manufacturing. I am also passionate about bringing about change in how the artisans are treated in this industry, by providing them benefits that they deserve to empower them,” she added. “It feels great to be part of the finalists this year. This win means that we are doing something right,” said Gaffane who walks away with prize money to the value of R300 000. Chief Executive Officer of the Eskom Development Foundation, Cecil Ramonotsi, remarked that this year the Foundation had made a concerted effort to encourage designated groups to participate in the competition. “Having a

Rachael Gaffane, founder of Danchi Group women-owned business walk away with the main prize vindicates our efforts to draw more participation from designated groups, particularly women, youth and people with disabilities,” he said. “On behalf of Eskom, I take my hat off for all the participants in the Business Investment Competition for having risen above their circumstances and pushing through adversity to realise their dreams of running their own businesses. In doing so, they not only succeed in generating an income for their families and employees, but also in creating much-needed economic opportunities for their communities and the country,” said Nthato Minyuku, Eskom Group Executive for Government and Regulatory Affairs. n

Cover story

Twinstar Precast –

The Custom Concrete Puzzle Solution Custom-built precast concrete products can often be the final pieces of a construction project puzzle: the perfectly-sized plinth, the architecturally perfect, but awkwardly shaped side-walls, the perimeter kerbs of a hospital helipad…

winstar Precast – one of the few custom precast concrete manufacturers – was founded with the objective of providing these critical pieces of the construction puzzle in the most reliable, cost-effective and client-centric manner possible. If you are wondering whether a particular puzzle piece could possibly find a concrete solution, Twinstar should be your first port of call. The effort and time required to design and build onceoff moulds for bespoke products can only be fully appreciated through hard-won experience. Simply surviving the first attempts requires methodical planning and an eye for optimisation (both budgetary and operationally). More self-styled fabricators than would admit to it have been bruised and burnt by underestimating the complexities of custom manufacturing. Proficiency in high-volume, rapid output manufacturing will soon seem rather basic, as the path to profit in custom fabrication reveals why so few have trodden it.

A well-founded operation Twinstar Precast was established in 2014 with the express aim of assisting specifying civil engineers and civil engineering contractors with complicated sites and situations where currently available precast concrete products would not work. The opportunity – the “gap in the market” – exists, as there will always be a demand for custom precast products. Success in custom manufacturing is itself custom-made. A business based on disruptive production set-ups and highly fluid operating procedures, not to mention the specialised skills and additional supervision so often required, contradicts business sense.

Walking the custom precast concrete walk “Our commitment to solving our clients’ specific needs requires our very personal involvement at all stages of the process,” explains director and founder Annemerie Coetzee. “Twinstar Precast is managed by two others and me and we’re on the factory floor most of the time.” The artisans, procurement and logistics specialists, machine operators and mould makers who make up Twinstar bring to the company their collective skills and operational co-ordination, acquired and refined by the extraordinary workflow demanded in order to deliver custombuilt precast products. “We’re very committed to every client who walks through our doors. We’ve accumulated the knowledge and developed the techniques and solutions required for even the most unusual designs and structural challenges through our own determination to solve every puzzle in front of us,” explains Coetzee. “We know how to listen to a client and make the impossible possible.”

Concrete Trends Issue 4 2021

Sized for quality, not quantity The values lived by Coetzee percolate through Twinstar Precast’s entire operation and, given the nature of its business, evidence of her integrity and personal commitment can be seen in the company’s continuous production of a staggeringly diverse range of products. “We’ve deliberately kept our operations sized for the work we deliver,” she explains. “I know exactly what we can commit to and precisely how to achieve the best outcomes for each client. We make our own moulds and have one truck with an excellent crane that enables us to deliver large concrete products in segments, to the great advantage of our clients. By keeping weight within the regulated range, we can save them hundreds of thousands of rands in transport costs. We’ll guide the placement and fitting of the product and will be on site, if necessary.” Coetzee notes that in most circumstances, Twinstar Precast has the capability to make adjustments to the design required. All practical considerations are done to ensure the product meets a client’s particular requirements.

The Twinstar “can-do” list Twinstar Precast’s expertise has been honed through both trial and error, as well as its willingness to try new solutions. The fundamentals that underpin its reputation include:

Cover story • Mould-making, including wooden, fibre-glass and polyurethane moulds. • The ability to tool up and supervise the precise process for each unique job. • Highly skilled specification and procurement of the right materials for each job, with the supplier network to guarantee satisfaction. • The ability to ensure a functional mould and move from potential time-frames to precise delivery commitment only when a mould is completely strippable. • Specialised experience in manufacturing the transformer and distribution boxes, plinths and cable markers for wind farms. • Being geared for private-sector construction requirements • The manufacture of standardised products for the public transport, infrastructure and housing sectors. • Laser-writing into the mould for mass-labelling of concrete components.

Hospitals, shopping malls and windfarms From specialised structures to weight-bearing delivery areas, shopping malls, housing complexes, hospitals and cultural centres, windfarms, roads, bridges, airports and bike racks, Twinstar is uniquely positioned to cater for an extremely diverse range of industries. The company is solution-driven in all aspects of precast concrete and creates products ranging in weight from 2kg to 6 tons. In 2018, it started with in-house manufacturing of polymer products. The risk of theft of products with steel and cast iron components increases daily. These polymer products have no metal components and reduce the safety risk of open manholes, as well as the financial implications these have for councils and developers. The company manufactures manhole covers and frames, as well as stormwater gratings. These components can be bought as loose items, or cast into the required precast concrete slabs The passion project of creating closures for decommissioned mine shafts in the Springs region of Ekurhuleni speaks

to Twinstar’s commitment to improving lives across the board and preventing potentially crippling injuries for a generation of children. The ability to deliver the highly specified components needed for windfarms has resulted in a very comprehensive list of SA’s existing installations, including: Noupoort; Loeriesfontein; Oyster Bay; Kangnas, near Springbok in the Northern Cape; Paardekraal in Ceres; Karusa and Soetwater in Sutherland; Khobab in Loeriesfontein; Gibson Bay; Nxuba in Bedford, Eastern Cape; and Garob in Copperton.

Markets and range Twinstar Precast has a unique relationship with mainstream precast concrete companies who pass on referrals and use it to supply certain non-standard products for their clients. As far as possible, the company uses small local suppliers and SMMEs, rather than large corporate companies, to supply its raw material. Twinstar Precast’s manufacturing facility is situated in Olifantsfontein, Gauteng and delivers anywhere in SA. Its crane-mounted trucks can offload products directly on site and can also help place slabs during installation. (These transport and installation services are available within Gauteng and the northern provinces.) n

Twinstar Precast (Pty) Ltd. Tel: 012 670 9083 or 082 552 1915. Email: info@twinstar.co.za I www.twinstar.co.za.

Concrete Trends Issue 4 2021

Event trends

African Construction Expo 2022 – Connection the construction industry in Southern Africa! The African Construction Expo is bringing the construction community together again in 2022, with its power of engagement, strategy and growth, combining to propel development, business and socio-economic acceleration.

he core of the exhibition’s success as a catalyst of regional economic growth and development is its focus on driving buyer and seller engagement in an environment geared to optimise their outcomes. By continuously improving the access to the knowledge, information and networking opportunities -before, during and after the exhibition – African Construction Expo 2022 is geared to maximise opportunities in construction for the benefit of the whole when it most needs it. The African Construction Expo will be co-located with Totally Concrete Expo, African Construction Awards, African Smart Cities Summit and more. The week of events will be held from 7 – 9 June 2022 at Gallagher Convention Centre, Johannesburg, South Africa.

“

Business networking, live product showcases and knowledge sharing experiences are back under one roof in Johannesburg with enhanced safety measures in place.”

Unparalleled Access: markets, people and projects The African Construction Expo is the only multi-disciplinary show within the construction industry focusing on engagement through collaborative content and face-to-face interactions under one roof. With thousands of attendees ranging from small contractors through to architects, quantity surveyors, property developers, government along with industry knowledge and product/service demonstrations for the entire value chain, it is the must attend event for the built environment. With 8 500+ construction professionals in attendance from across the globe, several months of customer engagement can be concluded in just 3 days.

Concrete Trends Issue 4 2021

Exhibitor access Exhibitors at the African Construction Expo 2022 will gain access to the most comprehensive market opportunities available at a crucial moment in the regions development history. United in prioritising construction as the driver of its recovery, the region’s construction sector is tracking a perfect storm of procurement activity. Exhibitors will have direct access to buyers, distributors, agents and construction professionals from the more than 46 countries in attendance. The African Construction Expo puts your business at the centre of Southern Africa’s booming construction market. Expand your network and learn about new markets and projects by taking part in the exhibition which will gather the entire built environment value chain. Product sectors include: • Building materials and tools • Building interiors and finishes • MEP services • Plant, machinery and vehicles • Green construction solutions • Smart/digital construction technologies and integrations • Totally Concrete The access to buyers on the exhibition floor is essential to exhibitors and part of the brilliantly targetable networking channels championed by African Construction Expo. From export opportunities to strategic connections to open up new markets, exhibitors will get the benefit and support of a dedicated marketing, ensuring face-to-face engagements with the regions key public, private sector, non-aligned and crossborder stakeholders from all tiers of government, state-owned enterprises, associations, consultants, projects owners, investors, bankers and more. To participate as an exhibitor contact KennethMasvikeni@dmgevents.com

7 - 9 JUNE 2022 | GAllAGHER CONvENTION CENTRE, JOHANNESbURG, SOUTH AFRICA

CONNECTING THE CONSTRUCTION INDUSTRY IN SOUTHERN AFRICA

SCAN TO EXHIBIT IN 2022

PUT YOUR BUSINESS AT THE CENTRE OF SOUTHERN AFRICA’S BOOMING CONSTRUCTION MARKET! Contact: Kenneth Masvikeni T: +27 21 700 5509 E: KennethMasvikeni@dmgevents.com

Co-located with:

AFRICAN

CONSTRUCTION POWERED BY: NAFBI

AWARDS

www.africanconstructionexpo.com

Event trends alone, African Construction Expo is targeting stakeholders and opportunities throughout the regions’ sectors. • Project Pipelines and Country Spotlights: ‘Country Spotlight’ sessions will focus on leading projects and opportunities specific to the Southern African region.

Voices from 2021’s “The African Construction Expo” digital edition:

Visitor access - exhibition, workshops, project showcases, site visits and networking The African Construction Expo 2022 builds on the innovations and experiences 2021’s digital event, bringing together the technologies, forums, workshops and project showcases with up-to-date market developments for an unparalleled insight into the construction sector. • Save time and money, accessing over 200 exhibitors showcasing the 1000s of innovative products, equipment and technologies from across the globe. • Expand your knowledge and skills at the free-to-attend CPD accredited workshops which give you insights into new products and strategies that will help you reduce costs, increase revenue and take advantage of new market opportunities, to sustain and propel business success. • Experience latest projects first-hand by joining us for various site visits to leading edge infrastructure sites • The Stakeholders Engagement Forum allows attendees to find out about the latest opportunities and challenges facing the local built environment whilst identifying new opportunities for communication and collaboration amidst public and private sector.

What’s new in 2022 The compelling need for all construction stakeholders to reconnect globally, and especially in Southern Africa, makes the introduction of disruptive technologies and sustainable innovations to be showcased across the construction value chain, one of the most exciting additions to 2022. These will include green construction, drone technologies, alternative building solutions, smart tech, and new integrations of technologies, equipment, machinery and vehicles. African Construction Expo will also bring much needed representation, expertise, knowledge, skills and products to its exhibition, forums, workshops, knowledge sharing session and other engagements focussing on: • Green Construction: The need for solar and alternative energy solutions is increasing throughout Africa at a rapid rate. Engineers, construction companies, builders and contractors must offer services to meet this need, as well as remain competitive • Financial solutions/funding bodies: The need to for improved access to funding options across constructions’ segments is urgent. African Construction Expo will ensure an increased presence from multi-lateral lending agencies, financiers, capital investors and equity innovators. • Low cost housing/student accommodation/medical facilities: With potential projects to the value of over R700-billion over the next 10 years (including both government and private stakeholders) for student accommodation

Concrete Trends Issue 4 2021

“A few days well spent. Well organised and efficient, with outstanding communication with yourselves and excellent feedback. Definitely not to be missed next year. Gallagher Convention Centre already diarised.” – Exhibitor “This Expo is an important event for anyone interested in construction, design, materials and products that serve architectural, structural and industrial systems. I advise colleagues to follow it.” – Attendee

So much more at African Construction Expo 2022 There can be no doubt that Southern Africa’s construction sector has much riding on it. From economic recovery, to job creation and sustainable transformation. Without the advent of the fourth industrial revolution, it would be an impossible ask. The integration of technologies with each other, with machinery, with networks, with vehicles that unlock this revolution must be embraced and explored by every segment of the construction value chain. The African Construction Expo 2022 brings it all together, and welcomes visitors and exhibitors to engage right now to get the maximum value for yourselves and for a region primed for accelerated recovery and growth. n

• Totally Concrete: – so central to fabric our modern world – has been under the spotlight for it massive culpability in climate change.The integration of technologies, processes, materials and chemistry so characteristic of the fourth industrial revolution and concrete’s adaptivity is driving a new world of concrete possibilities. Don’t miss this opportunity to bring you concrete and construction businesses along for this exciting ride. • Smart Cities Summit: summit, which will take on a digital format, aims to tackle the African definition of smart cities, debate challenges and discuss opportunities, as well as investigate the successes and let-downs the continent has seen thus far.. • Keynote and Stakeholders Engagement: In 2022, we will be joining the NAFBI Stakeholders Engagement Forum once again with potential to co-locate their leadership summit at the show. Government stakeholders need to be engaged with as a priority to gain their endorsement and support upfront. • Speaking Opportunities: If you have a smart cityrelated case study, practical application, or research based on an African country, we invite you to submit your 300 word abstract to be considered as a speaker at the 5th African Smart Cities Summit. Submissions to be sent to LindiweNkosi@dmgevents.co

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Safety trends

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ayne Safety has been Africa’s gumboot specialist for over 80 years. Since 1940, no other manufacturer has supplied more industrial and safety gumboots into the African market. Wayne Safety started manufacturing gumboots an incredible 80 years ago, with Wayne Rubber producing rubber gumboots in KZN. This began a long tradition of manufacturing superior quality gumboots and serving workers right at the heart of industry. Today, Wayne is one of the foremost PVC and PU gumboot manufacturers in Africa. The Wayne range of PU gumboots offers a variety of enhanced features and benefits, catering to sectors from food processing and hygiene to light and heavy duty agriculture. While PVC gumboots are reliable and economical, polyurethane (PU) gumboots are rapidly growing in popularity – and for good reason. One of the key advantages of PU gumboots is that they

Concrete Trends Issue 4 2021

can last up to 3 times longer than PVC boots, giving you a longer lifespan and greater value for money with no compromise on protection and resistance. To fully understand the benefits of PU gumboots, let’s look at the Wayne Pure Max PU boot as an example. Vertically-injected air bubbles in the Pure Max give the boot a lightweight, comfortable feel, while maximising resistance. An inherent cross-link structure delivers enhanced flexibility and strength, and gives the boot excellent insulation properties against both heat and cold. A multi-stage curation process results in a protective ‘outer skin’, which increases resistance and durability, while ultra-sonically welded controlling particles impart greater resistance to abrasions – further extending the life of your boot. Adding to these structural benefits, Wayne’s Pure Max gumboot has a range of added benefits. A unique treadgroove and depth gives our PU boots the highest possible SRC slip resistance rating. Optimum hygiene is ensured through the boot’s moisture wicking functionality, and anti-microbial and anti-fungal treatment; and a lightweight composition paired with a unique footbed results in all-day comfort. Last but not least, anti-static properties give the wearer peace of mind. But at Wayne, we know it’s not enough to tell you that our boots can deliver a longer lifespan of comfort, resistance and durability – we have to prove it. That’s why the Pure Max is flex tested to over 900 000 flexes, far beyond the industry standard of 30 000 flexes, showing no significant deterioration – that equates to over 900 000 steps, or over 700 kms! Trust in Wayne, Africa’s gumboot specialist for 80 years and counting, and get your Pure Max PU gumboots today. Find out more about Wayne’s range of superior gumboots at www.wayne-safety.com. n

Safety trends

Creating safe workspaces

ow do organisations provide a safe workplace? Keeping intoxicated employees out of the workplace requires clear anti-intoxication policies coupled with strict enforcement through employee testing. For alcohol, breathalysers are the most effective means of testing for intoxication and for substance abuse, saliva testing can provide immediate results detecting recent consumption effective within minutes after the use of drugs. Saliva testing is seen as less intrusive than urine testing and also more effective at determining recent consumption. Furthermore, the use of an oral swab to wipe the inside of the cheek means there are fewer privacy issues with this testing method, compared to urine collection.

younger population, as draconian implementation of substance testing and disciplinary action will only cause employees to be more devious in their attempts to conceal their substance abuse problem. Employee Assistance Programmes (EAP) in the workplace can be an effective means for individuals to come forward and admit to substance dependency and ask for help in dealing with their problem, without fear of disciplinary backlash. The specifics of each EAP initiative will vary from organisation to organisation – some assist employees by sponsoring their rehabilitation, but at the very least the individual should be afforded paid sick leave, making it possible for them to seek treatment. In addition to such a confidential facility, organisations need to prioritise the mental wellbeing of their workers, while educating and creating awareness around the dangers of substance abuse and the available options for treatment and recovery.

Even tougher times ahead As difficult as it may be to face, life is going to get a lot harder for South Africans as we continue to deal with the impact of a pandemic that shows no signs of disappearing. Access to state-provided mental health support is extremely limited in SA, which means that businesses will be required to step up during these tough times and prioritise the wellbeing of their workers. This is important not only from an occupational health and safety perspective, but from a business continuity perspective – people are the most important asset in any business, and right now those assets need additional support and assistance. n Most importantly, however, is how you engage your staff with your policy. In order to create safety, staff need empathy and the knowledge that this is an inclusive, non-threatening process. Staff cannot hear enough about your policies, how confidentiality works, and the options available to those seeking help. The cost of helping a teammate get better is always less than replacement, and the ripple effect of trust and buy-in around help also opens many doorways for all concerned.

Pay attention to the underlying problem Strict enforcement of anti-intoxication policies in the workplace should be counterbalanced by measures that seek to identify and address the underlying issue of substance abuse. This is particularly important right now given the collective mental fragility of our

ALCO-Safe Rhys Evans, Managing Director Tel: 012 343 8114 Email: rhys@alcosafe.co.za

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Industry trends

Cement quality paves way brighter economic future By ensuring that a high quality of cement is used in infrastructure, South Africa is investing for a stronger future, according to Richard Tomes, sales and marketing executive at construction materials leader AfriSam.

“W

ith our history going back 87 years, AfriSam has sustained a significant focus on quality which today pays dividends in terms of the structures relied upon by our people and our economy,” says Tomes. “By putting the best quality materials, expertise and technology into our products, we pave the way to a brighter and more reliable future.” The drive for quality is closely linked to being fit-forpurpose, he says, by ensuring that a range of cements is available for defined applications. In the housing sector, AfriSam has raised the bar with the quality of its All Purpose Cement so that it can be used for a number of purposes within this segment. “Contractors and home owners want to rely on a cement that will last, so that problems like cracks in walls do not occur,” he says. “At the same time, there may not be a high level of expertise among some users in this market, exposing them to a potential risk if they choose the wrong cement for the task.” Mixing concrete with a cement that has been developed only for plastering, for instance, could compromise the integrity of the structure. To avoid this risk altogether, AfriSam’s All Purpose Cement meets a high spec that allows it to be used for any home-building application. “Road building is another application where quality cement brings many benefits that end-users seldom even see or think about,” he says. “AfriSam’s Roadstab is a specialised cement that allows contractors to create a strong foundation for longer road life, while also giving them delayed setting time to conduct the necessary mixing and compaction.” By the same token, large structures need a cement which will reduce the heat differential between the inside and outside of a large concrete mass so that cracking does not occur. Special cements to achieve this have allowed South Africans to build vital structures like dams and wind farms, vital to our economic development. “As we start to experience the global challenges of climate change, it is not enough to focus just on the quality of cement products themselves,” says Tomes. “We need to innovate the process of how we manufacture these products, for a more sustainable future.” He highlights that AfriSam’s commitment to both people and the planet have ensured that quality processes have reduced the company’s carbon emissions to well below the international average for cement producers. It has even contributed to water savings by developing cements that consume less water when mixed to produce concrete. n

Concrete Trends Issue 4 2021

Industry trends

Advanced concrete technology training now in modular, self-study form Cement & Concrete SA’s School of Concrete Technology (SCT) has announced that next year, it will again offer the internationally recognised Advanced Concrete Technology (ACT) diploma course, the concrete industry’s most sought-after qualification

ohn Roxburgh, senior lecturer at the School of Concrete Technology, says that for the first time, the SCT50 Advanced Concrete Technology course will be presented in a modular, self-study format, rather than the traditional classroom/lecture system. “The decision to shift towards modularisation was made to attract potential delegates who lack the time for a John Roxburgh classroom-based course and to accommodate site staff experienced enough to enrol for this highly coveted diploma. Uncertainty about the future of Covid-19 lockdowns is also eliminated by the new format,” he explains. Roxburgh says that for the past 30 years, the SCT has worked closely with the Institute of Concrete Technology (ICT) in London to provide the SCT50 programme in preparation for the ICT Stage 4 diploma examinations. Dozens of South African students have excelled in the course and now hold top academic and industry posts in various corners of the world. Training for the ACT course will consist of five modules, with a textbook based on the structure of the highly-acclaimed 10th edition of Fulton’s Concrete Technology, the South African “concrete bible” launched by Cement & Concrete SA earlier this year. Students will also be supplied with supplementary reading material to ensure all topics in the ICT Stage 4 diploma examinations are covered. “Each of the first four modules of the training will have a workbook for delegates to complete. The workbooks – designed to challenge the students and provide practice in technology-based writing and thinking – will then be assessed by a lecturer at SCT, with satisfactory completion resulting in the student passing to the next module,” explains Roxburgh. Students can enrol for up to two modules at a time and the entire course can be completed within two years.

Roxburgh says the only entrance requirement for admission to the ACT programme will be a pass in both the ICT Stage 2 (SCT41) and Stage 3 (SCT42) examinations. Each of these courses is presented online by the SCT. “The modularized, self-study approach will ensure a better quality of concrete technology education and allow more time to study each topic in detail, while reducing the impact on students’ work commitments. It will also be more affordable, as students can now pay per module, without the need for a large upfront payment,” he adds. The modules cover the following topics: • Module 1: Materials and mixes • Module 2: Concrete properties • Module 3 Concrete manufacture, site practices, quality control and non-destructive testing • Module 4: Special concretes and techniques • Module 5: Concrete sustainability, statistics for concrete and a selected ACT project Roxburgh says the new self-study approach, which can be begun any time in 2022, will offer the following benefits: • More time to study, with the student setting their own pace. • More detailed study of each subject. • Stimulation of curiosity and a questioning approach to the various subjects. • Encouragement of resourcefulness in finding answers. • The use of a structured and logical approach to answering scientific questions. • Increased personal confidence in the application of concrete technology. Full details about the programme’s learning objectives can be downloaded from the ICT website (https://www.theict.org.uk/ Qualifications.asp) under the “Qualifications”. For further information, contact John Roxburgh on tel: (011) 315-0300 or e-mail: john.roxburgh@cemcn-sa.org.za. n

Concrete Trends Issue 4 2021

Industry trends

Sealants for high-profile industrial and highway projects

oint sealants and auxiliary products supplied by a.b.e. Construction Chemicals, part of the Chryso Southern Africa Group, have recently been specified for several high-profile projects in Gauteng and KZN. Firstly, Dowsil 890-SL silicone joint sealants, for which a.b.e. is the sole South African distributor, was specified as sealant of the external concrete hardstand area at DSV Park, a massive new warehouse complex near O.R. Tambo International Airport in Kempton Park for the major logistics company, DSV South Africa. Dowsil, (formerly Dow Corning), which produces its wide range of acclaimed sealants in Belgium and the USA, is widely recognised as a global leader in its field. For the construction of DSV Park, Dowsil 890-SL sealant was applied by a.b.e.-approved applicator, Safrispec, to the joints at an external concrete hardstand area of about 150 000m2. A total of 65 000 linear metres of the highly-regarded sealant had to be applied between 200mm-thick concrete surface panels that cover 2 300m2, says Jeandré Myburg, a.b.e. Technical Sales Consultant, based at the company’s Boksburg head office. Among the sealant’s features that influenced its selection by specifying engineers, MVW Consulting, and the flooring contractor, RCR Flooring Applications, are: • Self-levelling; • Movement capability of 100% for extension and 50% compression; • UV stability and weather-resistance; • Flows into irregular joint widths and does not require special application tooling; • No heating or special preparation required; • Short skin-over time of an hour or even less at standard conditions; and • Dowsil’s 15-year warranty on the 890-SL’s performance. Jeandré says a.b.e. also supplied various sizes of ultra-flexible a.b.e. dura.cord preformed joint filler, (manufactured from low-density, closed cell polyethylene), which form part of the material to seal the concrete joints.

DSV Park and left applying sealant application

Concrete Trends Issue 4 2021

The main contractor for the construction of DSV Park, completed in March this year, was WBHO. Dowsil 890-SL was also among the products supplied by a.b.e. for repairs of the failure of existing joints and sealants at the Gautrain Midrand bus depot. Grant Furrows, a.b.e. Technical Sales Consultant, who collaborated with Jeandré Myburgh for this project, says the sealing of about 40 000 linear metres was required for this project, being handled by ConSolve Civils and scheduled for completion in November 2021.

Gauteng Bus Depot depot hardstand area “a.b.e. is also supplying dura.rep FMC cement-based concrete grouting for the joint repairs at the bus depot. This popular product is non-shrinking with aggregate and additive content that prevents segregation during application, as well as improved strength and low permeability,” Grant explained. “a.b.e.’s epidermix 344 epoxy adhesive, with its exceptional strength and bonding capacity, is also being used for the refurbishment of the depot’s concrete surfaces.” Finally, 22 000 linear metres of Dowsil 890-SL joint sealant, which can also effectively be applied to seal joints on high-traffic roads, has been specified for the N2 concrete highway’s realignment at the northern ends of the Umhlali and Umvoti bridges in KZN. The aim of the long-awaited SANRAL project is to flatten sharp corners to increase safety on the busy highway and reduce the high number of accidents that have occurred in the past in the areas under realignment. Darryl Laycock, Technical Sales Consultant at the a.b.e. KZN branch, is assisting the specialist sub-contractor, Duncan Civils, in a supervisory capacity in the application of a.b.e. concrete repair products (dura.rep ZR Primer, epidermix 345 wet-to-dry epoxy, and dura.rep FR), used specifically on the bridge structures, as well as Dowsil 890-SL highway sealant, and the dura.cote WB coating system, for this project. The overall contract was awarded to Raubex KZN who appointed a.b.e. – approved applicator, Duncan. n

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All States Concrete Equipment Africa

Building partnerships one floor at a time

ven Schutte is the South African representative of All States Concrete Equipment, a concrete equipment business established more than 30 years ago, and a growing presence in South Africa. As a specialist contractor in concrete finishes in South Africa, Schutte’s work with All States Concrete Equipment gave him an edge in the quality for cost he could provide the local market. “All markets have their own peculiarities, and South Africa perhaps has more than some. In the concrete flooring and finishes segment, there is definitely space in the market for specialist contractors, able to bring the granular knowledge and equipment to projects often reserved for larger players and sub-contractors.”

Partnerships for growth Representing an incredibly extensive product range, including Ligochine’s range of boom and drive-in screeds and Masterpac’s innovative compactor technologies, All States Equipment Africa brings together an offering of global standards, fit for local market conditions. “To really benefit from these products in the South African market, it is essential be a true partner to our customers,” explains Shutte. “The first step is the most important: making contact. From there, we work very steadily with our customers, understanding their businesses and goals and developing a product plan that is affordable and will give them not only the technical results, but the best shot for projects that may once have seemed out of reach.”

from specialty contractors…. From retail spaces, commercial office spaces to large industrial spaces, there are many technical routes to the desired finished product. With the right selection of tools and machinery, coupled with the knowledge and support of All States Equipment, contractors can develop speciality services at competitive rates and build the businesses on results and reputation..

…to construction companies The benefits of owning large screed and compaction equipment include the ability to make a complete offering, and rule out the nuisance factors that sometimes develop between contractor and subcontractor. With the right network of machinery and skills, the ability to take full control of projects is one step-closer with All States Equipment. The perfectly levelled, flattened floor with finishes required are well within reach with the versatility and support of All States Equipment Africa.

Flawless floors minus the issues Schutte vision of concrete flooring is the right equipment and the right focus at every step of the process At every step of the process, the correct execution of required processes is envisioned through the equipment and tools to be used on a project. As Shutte point out: “A clear example of getting something right the first time is the differ-

Concrete Trends Issue 4 2021

SPIDER SCREED

BN446 POWER TROWEL

GRINDERS

HAND TOOLS

BN46H RIDE ON POWER TROWEL

PLATE COMPACTOR

COMPOUND SPRAYER

MASTERVIBE

BULLFLOATS

BN424 EDGER

ROAD SAWS

ence between flattening and levelling. The expense and structural risks of grinding uneven floors, resulting from focussing too much on levelling, and not enough on flattening, is a prime example of unnecessary and complicated corrective work.” he explains. The ability to recognise these differences and implement correctly from the get-go is what All States Equipment is all about. The opportunity to build any business on a reputation for excellence and delivery begins with a simple email. Five steps to a hassle – free project • Step 1: Contact All States Concrete Equipment by emailing “Five Steps” to sales@allstatesafrica.co.za • Step 2: All States Africa Concrete Equipment will do a comprehensive quote for all consumables required for each project. • Step 3: You will place one Purchase Order per project with All States Africa Concrete Equipment. • Step 4: All States Africa Concrete Equipment delivers all consumables for each project in a 6m container free of charge. The container remains on site until project completion. • Step 5: Use consumables hassle free on site and at the end of each month All States Africa Concrete Equipment invoices each project based on the consumables used for that month only. The benefits of partnering with All States Concrete Equipment are immediate. Having a single project owner per project is time and money saver second-to-none. Having control over a budget, fully protected from the unforeseen come a very close second though. The ability to get all the equipment on-site at once frees the team to concentrate on the job at hand, and the on-site storage facility brings immediate convenience and peace of mind. Being secure that the cost of the consumables is limited to their use over a given month secures cash flow as well. All States Concrete Equipment Africa – it all starts here: sales@allstatesafrica.co.za n

Innovation trends

Reduce water – add another step to sustainability

esponsible contractors have realised the growing strain on South Africa’s scarce water resources, and a new admixture is geared to conservation efforts with its water-reducing admixtures for concrete. A recent example of this was in the construction of the Vlakfontein Reservoir near Standerton in the province of Mpumalanga. This is probably one of the largest cylindrical posttensioned concrete reservoirs in the world, with an inner diameter of 154 metres and a heavily reinforced 11,8 metre high wall.

A dynamic mix According to Patrick Flannigan, technical manager: concrete business unit at CHRYSO Southern Africa, the project made use of several admixtures to reduce water and improve workability. “One of these is our Plast Omega 178 plasticiser which, when used in a concrete mix, permits a reduction in water content without affecting the consistency, also referred to as the workability,” says Flannigan. “It can also increase the slump – or flow – without affecting the water content of the mix.” The Vlakfontein Reservoir has a ground water drainage system constructed with three layers of 5 MPa no-fines concrete. The 8 000 m3 of no-fines concrete comprises a 50 mm thick layer of 9,5 mm stone mix, followed by a 245 mm and 125 mm layer of 19 mm aggregate. To facilitate consistency and ensure the aggregate would bind mechanically and hydraulically, CHRYSO® Easydrain was introduced to these mixes to the cement paste. This specialised admixture fluidises the concrete, assists with a homogenous

Evaporation was controlled using CHRYSO Profilm 19 evaporation reducer at the Khutsong reservoir project mix and improves curing to reduce the chance of cracking. The bonded aggregates, once dried, will not loosen. An additional drainage layer of around 2 200 m3 of no-fines concrete will be poured around the reservoir.

Khutsong Reservoir – the first time a pre-tensioned floor was used for a reservoir in Africa

Concrete Trends Issue 4 2021

Innovation trends

Khutsong Reservoir under construction Once the no-fines concrete was completed, a layer of 200 mm 35 MPa concrete was pumped in 13 pours of approximately 250 m3 each. This mix included CHRYSO® Serenis, a shrinkage reducing admixture. This, together with CHRYSO® Omega 178 superplasticiser, reduces water and assists with workability. CHRYSO® CWA 10 crystalline waterproofing agent will provide integral waterproofing and reduce permeability in the concrete. The crystals prevent water penetration and protect the concrete against corrosive ground water and chemicals. CHRYSO’s water-reducing admixtures were also used in the Khutsong Reservoir near Carletonville in Gauteng. Due to the danger of sinkholes in this region, and the possibility of ground movement, the reservoir is the first to be constructed with a pre-tensioned concrete floor.

Situated near the Putfontein offramp, the 210ml Vlakfontein reservoir has a project value of R100M+

Concrete Trends Issue 4 2021

The scale of the work required 212 truckloads of concrete for the floor, successfully poured within a day. The 1,267 m3 concrete floor used pumped mixes at 35 MPa at a thickness of 450 mm. In this demanding contract, the concrete mix included CHRYSO® ZA 1559, a new generation, multi-dose water-reducing plasticiser.

Broad applications, many advantages “This admixture allows a wide range of dosages to be applied, without any excessive retardation at the higher dosages,” he says. “The multi-dose characteristic of CHRYSO® ZA 1559 also gives concrete extended workability characteristics.” Flannigan notes that it improves the cohesion and lowers the viscosity of a concrete mix. This results in an improved homogeneity and compaction, allowing for superior off-shutter finishes. With less need to add extra water, CHRYSO® ZA 1559 reduces the permeability of concrete, thereby improving is durability. “The product may be used in mixes extended with limestone or commonly used supplementary cementing materials (SCMs) like ground granulated blast furnace slag (GGBS), fly ash and silica fume,” he says. “At the same time, it does not undermine the early age strength of concrete. In fact, in certain cases, it may be used to improve it.” CHRYSO® ZA 1559 has applications in readymix concrete and mechanically mixed site concrete, as well as conventionally placed, pumped and highly reinforced concrete. It conforms to the requirements of SANS 50934-2 (EN 934-2) standards, which are approximate equivalents of ASTM C494 Type A. Water evaporation was successfully controlled with CHRYSO® Profilm 19 evaporation reducer, while shrinkage of the reservoir floor was reduced using CHRYSO® Serenis shrinkage reducing agent. A minimum of 180 litres of water per m3 had to be used and fly ash was added as the heat of hydration had to be controlled due to the mass pour. The end strength did not exceed 45 MPa. n

Project trends

Hollowcore slabs eliminated the need to install tons of support and scaffolding

Suspended precast slabs accelerate delivery

new development that will provide accommodation for a large international contracting team that has been appointed to work on an industrial project in Limpopo is progressing ahead of schedule. This is only two months after the building contractor, Projects 2000, broke ground on this R32-million building project. The impressive progress made in such a short timeframe bears testament to the vast skills and experience of the entire professional team, which also includes Cosmoplan Architects & Industrial Designers; Fanoy Consulting, the consulting engineer; MVM Africa Electrical Engineers and Quanto 2000, the quantity surveyor. This is in addition to specialist subcontractor, Coreslab, which manufactured and installed the many hollowcore slabs that make up the floor space of this development, which includes two sleeper blocks and a lodge.

No scaffolding, no limits

4 Days

Fully delegated to experts

The company’s suspended slab solution played a critical part in helping the contractor to significantly accelerate the works programme. A total 1 170m2 of hollowcore slabs were installed by Coreslab in only four days. This enabled the contractor to commence fitting out the rooms below and with the brick work above almost immediately after they were installed. The hollowcore slabs are manufactured to the highest quality and cut-to-size at Coreslab’s factory. They are then transported to site where they are positioned onto the loadbearing walls and grouted into place according to the building plan. This is before they are covered with either a 30mm topping or 50mm structural screed, depending on the engineer’s requirements. Core-drilling is then undertaken to create voids for the electrical services to complete the installation. The contractor would have never achieved this impressive production rate if it had used conventional cast-in-place methods to construct the floor slabs. This is considering that it takes up to 28 days for concrete to cure before the shutters can be stripped so that work can commence above and below the slab.

Alternatively, the contractor could have batched and pumped its own concrete on site. However, this would have possibly delayed the project, considering the need to introduce extra

The use of hollowcore slabs also did away with the need to install tons of support and scaffolding in preparation of the concrete pours for traditional in-situ slab construction. Extensive propping underneath the slab also restricts trades from working below on a conventional building project. Moreover, the solution eliminated the need to coordinate a large team of rebar and shutter hands, as well as the delivery of construction materials to a very remote worksite. Rather, Coreslab’s hollowcore slabs are manufactured in a controlled factory setting that is far removed from the many variables on a construction site. They are dispatched to site on a just-intime basis and lifted directly from the truck trailers using one of Coreslab’s mobile cranes. This also frees up available space on building sites.

Concrete Trends Issue 4 2021

Project trends

A total of 1170m2 of hollowcore slabs were installed by Coreslab in only four days quality control measures. For this reason, Projects 2000 decided to also rule out the use of rib-and-block systems to construct the suspended concrete slabs. Projects 2000 would have had to install this system itself. By delegating the construction of the suspended slabs to a specialist in the field, potential errors were mitigated to ensure a finish of the highest quality the first-time round. The use of hollowcore slabs also provided a safer solution by doing away with the need to work at heights on scaffolding. The precast concrete elements are manufactured at ground level in the factory and installed on site by a small team of skilled and experienced workers. This includes a foreman, surveyor, rigger and crane operator. Notably, there has not been a single lost time injury on this project – in line with the mine’s own strict occupational health and safety protocol.

A timeline to behold Coreslab undertook its first site visit on 2 June 2021 when Projects 2000 was still at foundation level for the three structures. By 27 June 2021, Coreslab had surveyed the three blocks, completed all its inspections and manufactured the precast-concrete elements. The first slab was placed on 2 July 2021 at 13h16 and the entire installation was completed on 3 July 2021 at 09h01. “This project was certainly not without its challenges, considering its fast-track nature and that the worksite is located about 300km from our factory. It just goes to show that nothing is impossible for Coreslab, especially when great team dynamics are involved. Projects 2000 worked at an impressive rate, so we had to constantly think on our feet to devise solutions very quickly to avoid delaying the principal contractor and to satisfy the end client. There was also no available cellular signal on site, so we had to communicate via Whatsapp. Countless calls were made between me and Thomas White of Projects 2000 to quickly troubleshoot to keep the project on schedule,” Johan Muller of Coreslab says. Johnny O’ Reilly, owner of Projects 2000, says that the company has been constructing concrete floor slabs in this

Concrete Trends Issue 4 2021

The company’s suspended slab solution played a critical part in helping the contractor to significantly accelerate the works programme

Project trends manner for many years and, in most instances, has relied upon Coreslab to provide the company with the service.

How it works “Coreslab is known for the very high-quality of its precastconcrete elements and installation work – so much so that we even refer to hollowcore slabs as ‘Coreslabs’ within the company. It was a given, therefore, that we would approach this longstanding partner to assist us with fast-tracking yet another project,” O’ Reilly says. Projects 2000 was appointed as the principal contractor for this development based on the company’s more than 20-yearlong legacy delivering quality real-estate development assets in the larger Limpopo province. They include malls, as well as commercial and industrial space. The two two-storey “sleeper” blocks together house 80 rooms, while the lodge includes administrative space, a kitchen, lounge and bar, in addition to a swimming pool. The four structures have an industrial look and feel in line with the clients’ brief to provide cost-effective yet quality accommodation for members of the contracting team, which includes highly qualified and senior personnel.

Challenges and innovations The project also provided ample opportunity for Projects 2000 to innovate. Among the challenges was completing a R32-million development in the four-month contractual period while also working in an extremely outlying area of the province. The construction site is located on a game farm within vicinity of the industrial project. To mitigate delays, site surveying started many weeks prior to the contractor breaking ground to commence working on the project. Essential construction materials were also procured and stored in a laydown area on site well ahead of the construction commencement date. This included, among others, the bricks, as well as flooring, wall tiles and roof trusses required for the project.

What a site! A large builders camp also had to be established on site to provide convenient accommodation for the many people who would eventually work on this project. This is considering that the closet urban node is located about 300km from the worksite. With employees located on site, work could also commence very early in the mornings to mitigate delays. This is in addition to providing a more cost-effective solution than having to transport workers to and back from the construction site every day. Between 150 and 170 people worked on this project when it peaked earlier this year, and up to 60% of the total workforce consists of members of the many subcontracting teams. Louw Whitehead of Cosmoplan Architects & Industrial Designers is also very impressed with the way in which the project has progressed thus far and looks forward to its completion well ahead of the contractual completion date.

Utility and fidelity “Coreslab has demonstrated once again that hollowcore slabs are an ideal solution for any fast-track project, again complet-

ing the installation with minimal effort,” Whitehead says. “I have also visited Corelab’s factory in Polokwane on a number of occasions and remain very impressed with the quality control measures in place there to ensure outstanding workmanship on all its projects.” Moreover, he credits Projects 2000 for its sound upfront planning that has also contributed to a successful outcome thus far. Only 5 000 bricks will remain out of the 700 000 ordered for this project once the project is completed – as just one example of the high levels of accuracy achieved by the professional team during the early planning phases. Whitehead considers this development to be one of his many flagship projects. This is considering the extent of innovation that had to be deployed by the entire professional team to deliver the infrastructure in such a short timeframe. Extensive modifications also had to be undertaken to the original design while construction was underway to contain costs. This required careful planning by the design and contracting teams to avoid costly delays. A case in point is the innovative planning of the services in-and-around the shaft to maximise the use of minimal floor space in the rooms. The rooms are about 16m2 and feature a work area and amenities.

Adding to sustainability Moreover, the design incorporates many cost-effective “green” elements to reduce its energy use. He specified heat pumps that only use a quarter of the electricity required by a geyser, while also being a more affordable alternative to solar water heaters. The bedrooms and entertainment areas have been positioned to receive direct sunlight and take advantage of cooling breezes throughout the day. Aerolite in the ceilings also lowers the natural exchange of heat that occurs in the building. Roof tiles were chosen because they stabilise the building’s interior temperature and, in so doing, reduce the need for heating and cooling. They were also a more cost-effective solution than IBR sheeting to cover the roof. He also included light-emitting diodes in the design wherever possible to reduce the draw on energy. The structure has also been designed to accommodate a large solar photovoltaic installation at a later stage. Importantly, Whitehead also designed the “sleeper blocks” and lodge area to cater to the needs of disabled people. Muller says that the Coreslab team is proud of the part it has played in this project and looks forward to working with the Projects 2000, Cosmoplan Architects & Industrial Designers, Fanoy Consulting and Quanto 2000 on future landmark developments. n

Concrete Trends Issue 4 2021

Project trends

An artist’s impression of the majestic block that anchors the development

The right mix of concrete casts new light on affordable housing

onstruction is underway at Paarl Rock, the fifth building in Concor’s 22-hectare Conradie Park development in Cape Town. Piling for the eight-storey block began in May 2021, marking the start of a one-year building programme, according to Mark Schonrock, property development manager at Concor. Paarl Rock will comprise 266 architecturally designed apartments in an affordable model for first-time home owners.

piles. With depths of 8 to 11 metres, the piles could be completed in just three weeks, Schonrock says, improving the pace of the project. “We have also installed two tower cranes – a 55 metre jib and a 45 metre jib – to facilitate our programme of work,” he says. These will lift and move concrete for vertical columns, as well as reinforcing bars for slabs and columns, and all formwork around the site.

Pile it up

The beauty of slabs below the surface

The block is underpinned by 158 continuous flight auger (CFA) piles, which present a quicker solution than bored or driven

Horizontal concrete slabs will all be post-tensioned, a current efficiency trend which reduces the amount of costly rebar

Current rental stock units being constructed, gearing up for first tenanting towards the end of this year

Current works on site progressing well with the rental stock units

Concrete Trends Issue 4 2021

A view of the overall site with roads and bulk services installed

Project trends required. The planned slab thickness has also been slightly reduced, from 285 mm to 255 mm. While a relatively small reduction, this will allow a saving of some 450 m3 of concrete over the planned area of 15,000 m2 of slab work. “Pouring of slabs will be conducted by a truck-mounted boom placer, which enhances construction efficiency especially where large continuous pours of 200 to 220 m3 are required on this project,” he says.

Mixed-use on the rise The Paarl Rock block will include ground floor retail space, two lifts and a roof top deck on the sixth floor looking westwards at Devil’s Peak and over the Cape Town central business district towards Signal Hill. To minimise the cost of long-term maintenance on the outside walls, the design makes use of face brick – but with a difference. “Different colours and shapes of face brick have been specified to create texture and variety in the façade,” he explains. “Patterns are also created with rustication, using bricks of different shapes or with varied orientation.” A perforated design is also used for the brick walls in front of drying yards, letting through light and air while also giving an attractive texture to the building façade. The laying of face bricks requires a somewhat elevated level of skill and attention, and also takes longer, so the best artisans are put onto the rustication work.

Construction progressing well at the Conradie Park development benefits to users. An on-roof solar generator will assist in ‘overheating’ water during the day in a specially-designed storage vessel to around 85 to 90 C. “Tapping into off-grid power in this way means that residents can save on what they pay in water-heating bills,” he says. The development is also conserving water and reducing water costs by supplying its own irrigation needs from a master incoming line of treated effluent – at just five to 10% of the cost of potable water. The water quality from this line, which is clean enough to be discharged into river systems, is further treated on site and also used for all irrigation and cleaning purposes. Concor has been on site at Conradie Park – where the old Conradie government hospital closed about a decade ago – for about two and a half years, preparing the infrastructure for the developments.

Public utilities

Overhead shot of the site, showing the public precinct starting to take shape, main entrance circle, town square and Heritage Precinct

Roads have been installed, along with stormwater drains and a dedicated sewage reticulation system. A pump station was installed to move sewage over the Elsie’s River canal to the main Athlone sewer system and three new electrical substations were constructed. The Conradie Better Living model is one of seven ‘game changer’ projects which has been prioritised by the Western Cape Government. This aims to improve the lives of citizens through the Finance Linked Individual Subsidy Programme, providing affordable housing situated near the city’s main arterial routes and job opportunities. n

Building skills beyond just labour Schonrock notes that Cape Town still offers a good pool of bricklaying skills, but the long period of depressed conditions in the sector is going to be felt in skills supply as building activity improves. As part of its corporate contribution to skills development, Concor conducts a range of training on its Conradie Park site. “Through the National Youth Service programme, for instance, we are training six local bricklayer learners,” he says. “Beginning in November 2020, they completed a six-month training course and were then placed with selected sub-contractors to work on the current project.” Paarl Rock’s innovations include an energy-efficient hot water system for residents, lowering their cost of living and taking load off the national grid. A centralised hot water generation system on the ground floor raises the upfront cost but provides many long-term

An artist’s impression inside one of the units with plenty of light and views

Concrete Trends Issue 4 2021

Contracting trends

The new road to outcomes and performance Output and Performance-based Road Contracting (OPBRC) is improving efficiency and effectiveness of road asset management and maintenance in various African countries. Ghana is the latest country to adopt this innovative contracting model to help solve the challenges encountered with conventional contracting models.

The OPBRC is for the design, rehabilitation, improvement, maintenance and complimentary interventions for selected feeder roads and farm tracks in the Upper West Region of Ghana

halen Jangali, a JG Afrika Technical Director of Roads and Highways and an expert in OPBRC, believes that there is more scope for other countries to adopt this model of contracting considering its many benefits. “OPBRC ensures quality design and construction of road infrastructure. This is in addition to facilitating the completion of road construction projects within the awarded price and adequate maintenance of the infrastructure after it has been built. There is a strong case for its deployment in other countries, including South Africa,” explains Jangali.

New expertise JG Afrika is among only a few South African consulting engineers that has broad knowledge in the field. This includes the company’s participation in successful road construction projects in Liberia under the OPBRC model. Based on Jangali’s stellar performance on these projects, he was recently nominated to lead the large team of JG Afrika engineers working on a large road construction project in Ghana that involves this method of contracting. His team comprises 10 seasoned geometric and pavement design engineers from the firm’s Pietermaritzburg and Cape Town offices. These skills and experiences are complemented by those of representatives from Ghana-based Taivani Consult, JG Afrika’s Ghanaian Joint Venture partner that is undertaking the geotechnical investigations and site surveys for this project, including hydrology and hydraulic design of the roadway drainage. The firms are joined by Attachy Construction, a Ghanaian

Concrete Trends Issue 4 2021

contractor, to complete the Construction Entity that was appointed to design, construct and maintain the road network on behalf of the Ghanaian Ministry of Roads and Highways.

Road users drive the terms An important feature of an OPBRC is that any type of firm or business venture that has the necessary technical, managerial, and financial capacity to fulfil the contractual obligations can be appointed to undertake the road works if this is permitted in the bidding document. This entity is responsible for designing and undertaking the works, services and actions that are necessary to achieve and maintain the service levels specified in the contract. These are defined from a road user’s perspective and may, therefore, include factors, such as average travel speeds, riding comfort and safety features. Notably, this is the first time that the Ghanaian Ministry of Roads and Highways is using the OPBRC model. The ministry decided to experiment with it based on the success of the system in addressing the limitations of traditional road construction contracts in other West African countries, including Liberia.

The Ghanaian project The OPBRC is for the design, rehabilitation, improvement, maintenance and complementary interventions for selected feeder roads and farm tracks in the Upper West Region of Ghana. This project comprises three lots which, together, total more than 670km.

Contracting trends JG Afrika, Taivani Consult and Attachy Construction were awarded Lot 3, consisting of a 225km network of feeder roads within the Nandom, Lawra and Lambussie Districts. “The initial rehabilitation of and upgrades to the roads includes the installation of streetlights, as well as the construction of sidewalks, bus bays and stopping lanes within selected urban areas. A total of 3,3km of roads in built-up areas will also be widened and upgraded from gravel surface to paved standards using concrete paving blocks. Moreover, existing culverts and new culverts will be constructed as part of this aspect of the work scope,” Jangali says. “Meanwhile, the maintenance component of the OPBRC includes complementary interventions, such as minor rehabilitations and the provision of mechanised boreholes with storage facilities at selected community-based health planning and service compounds. Periodic maintenance works consist of specific re-graveling activities and emergency works have been included in the network performance component of OPBRC.” Located within the Western Sudan Savanna Zone, the network of feeder roads mainly services agricultural operations. These include, among others, the production of food crops, such as millet, sorghum, maize, cowpea, groundnut, rice and yam. The network traverses a level terrain with an average elevation of 300m above mean sea level (MSL). With elevations ranging between 180m and 350m above MSL, the terrain generally slopes gently towards the Volta River. The lowest areas lie along the Volta Lake. The construction entity is responsible for maintaining the road for three years after the two-year-long construction phase. In this way, the OPBRC also expands the role of the private sector to the management and conservation of road assets. This is opposed to the traditional role of a contractor which is to only execute the works. Under the conventional contract model, the contractor is incentivised to undertake the maximum amount of works to increase its turnover and profits. The contractor is not responsible for the quality of the design of the road for the user – even if it has spent a large sum of money and executed the work according to the contract. This has led to instances where roads have not lasted because of deficiencies in the original design and inadequate maintenance.

The workload required to ensure that the service levels indicators are met will vary from one month to the next. However, the monthly payment remains the same as long as the contractor maintains the required service levels. Notably, OPBRCs incentivise the construction entities to be efficient and effective whenever they perform work. To maximise profits, they must reduce work to the smallest possible volume of intelligently designed interventions, while also ensuring that they achieve and maintain the pre-defined service levels over time. Sound managing capacity is essential to ensure that the standard of the roads remain above the agreed service levels. This requires an ability to timeously define, optimise and perform the physical interventions that are needed in the short, medium and long term. Under the OPBRC, routine maintenance consists of various duties that need to be undertaken frequently to maintain the road’s functionality. Among others, this includes repairing potholes, cleaning drainage, sealing cracks and clearing vegetation. Periodic maintenance comprises predictable and more costly measures of a less frequent nature that will mitigate the degradation of the road over time. This includes, for instance, grading, drainage work, resurfacing and asphaltic concrete overlays.

Contract development During the bidding process, the construction entity proposed a fixed lump-sum prices to raise the road to a certain service level and to maintain this standard for a relatively long period. Under the OPBRC, the construction entity does not get paid directly for inputs or physical works. Instead, it is remunerated for achieving the specified service level indicators of the OPBRC. This includes rehabilitating the road to pre-defined standards; maintaining certain service levels on the network; and performing specific improvements to the infrastructure. It will receive a monthly lump-sum that covers all the physical and non-physical maintenance that it provides, while unforeseen emergency works will be remunerated separately. The rehabilitation and improvement work, which have been explicitly specified by the Ministry of Roads and Highways in the contract, are quoted on the basis of measurable output quantities and paid as performed by the construction entity. To receive monthly payment for maintenance services, the construction entity must ensure that the roads under the contract meet the service levels indicators as specified in the bidding document.

JG Afrika, Taivani Consult and Attachy Construction were awarded Lot 3, consisting of a 225km network of feeder roads within the Nandon, Lawra and Lambussie Districts Jangali says, “Intelligent management, timelines of interventions and appropriate technical solutions are key to the success of OBPRCs. This is where this model of contracting harnesses the skills and experience of the private sector to ensure significant efficiency gains and innovation.” Under the OBPRC, the construction entity will also be responsible for the continuous monitoring and control of road

Concrete Trends Issue 4 2021

Contracting trends conditions and service levels included in the contract. This will enable it to fulfil the needs of the contract and provide information on compliance with service level requirements. They will also help inform, plan and define interventions to ensure that service quality indicators never decline below the indicated thresholds. Notably, the employer does not instruct the construction entity on the type and volume of road maintenance works that need to be undertaken. Instead, the onus lies with the construction entity to ensure that it delivers a service according to expectation. He says this is how the OBPRC again ensures efficiency gains and technological innovation by harnessing the skills and capabilities of the private sector.

Preparing the engineering work Notably, this type of procurement also requires sound preparatory engineering work. This includes compiling comprehensive information on the actual condition of the roads that are covered by the contract. If rehabilitation works are required, the employer defines the level of quality or standard that needs to be achieved by the contractor for delivery and completion. For improvement works, a well-designed bill of quantities that defines specific outputs for bidders to price is prepared. This is later used to measure and pay the construction entity. A unit price bill of quantities with estimates is prepared for emergency works for bidders to price for bid evaluation purposes. These unit prices and real measured volumes of emergency works executed are used to pay the construction entity. Another important area that requires sound engineering advice is whether the rehabilitation works should be included in the contract or be undertaken in advance under a separate standard civil works contract. This decision depends on the ability of the construction entity to cost-effectively administer the risk. Generally, when initial works represent more than 40% to 50% of the contract value, the risks may be considered too high warranting an initial separate contract. However, this document needs to be adapted if the employer wants the rehabilitation works to be based on a pre-defined design and

connected to future maintenance by the same contractor. In this case, the bill of quantities for rehabilitation works will be modified so that they are similar to those for the emergency works. The measurement and payment clauses should also be modified for an “input” type contract. JG Afrika and Taivani Consult commenced with the full engineering design, spanning field work through to pavement design, in August 2021. They are working to very tight deadlines to make up for minor delays due to logistical challenges. The design of the 225.3km of roads needs to be completed within seven months so as to avoid delaying the construction works which will be supervised by a monitoring consultant that is still to be appointed. Taivani Consult has to travel about 600km from Accra to the construction site to complete the surveys and geotechnical studies. The engineers fly from the capital city to Wa and then travel via road to the site.

Integrated digital communications Extensive use is also being made of digital communication technologies, such as Microsoft Teams, to ensure ongoing communication between JG Afrika in South Africa and Taivani Consult in Ghana. These tools, which were also very effective when restrictions on cross-border travel were implemented to curtail the spread of the COVID-19 virus, will also be used to ensure continued interaction between the various participants in the construction entity during the subsequent phases of the OPBRC. Jangali lauds the Ghanaian Ministry of Roads and Highways for its innovative approach to road construction that will also ensure the efficient use of public funds. “Importantly, these contracts are also assisting governments build experience in undertaking public-private partnerships. This is in addition to changing the public sector’s role from being a purchaser of goods or inputs to a purchaser of services – a significant change in traditional relationships between professional teams and client bodies,” he concludes. n

This is the first time that the Ghanaian Ministry of Roads and Highways is using the OPBRC model

Concrete Trends Issue 4 2021

Strategic trends

Aim to thrive, not just survive

he construction industry has been navigating a challenging landscape due to the economic slowdown caused by the COVID-19 pandemic. The sector has historically been highly sensitive to economic cycles that have been compounded by government-sanctioned lockdowns, leading to the delay, suspension and cancellation of projects around the globe. Initially, the pandemic disrupted all types of construction, but 18 months in, the impact is diverging. Commercial construction activity in industries that have thrived during the pandemic, including technology, distribution, life sciences and healthcare, has rebounded – and even accelerated. Meanwhile, construction activity in more discretionary sectors including retail and hospitality, are yet to return to anywhere near prepandemic levels.

“

…adopting the use of prefabricated items to allow for less people on site in addition to a ‘plug and play’ approach that reduces time spent on site.”

Don’t shy away The industry is confronting substantial risk from a shortage of materials and talent due to mobility restrictions caused by the pandemic. This risk is compounded by the uncertain pace of recovery. Evidence that the pandemic is under control — such as proof of high vaccination rates with high-efficacy vaccines – is needed to gain support and accelerate deployment of investments. According to Aon’s 2021 Global Risk Management Survey, The top 10 risks facing the construction industry are: 1. Economic slowdown 2. Commodity price risk, scarcity of materials 3. Cash flow / liquidity 4. Business Interruption 5. Accelerated rates of change in market factors 6. Cyber risk / data breach 7. Workforce shortage 8. Capital availability 9. Damage to reputation / brand 10. Pandemic risk / health crises

Key issues for the construction industry The COVID-19 pandemic is a defining event, and most of the construction industry’s top risks, including scarcity of materials, liquidity risk and workforce shortages, flow from it. “In some African countries, scarcity of materials as well as workforce shortages are a challenge,” cautions Tshepo Mofubetsoana, Aon South Africa’s Senior Broker in its Construction, Engineering and Renewable Energy Division. “Specialised machinery and equipment are in short supply and if they are available, the job sites are often so remote that it is nearly impossible to get the necessary resources there. But the continent is developing and as infrastructure grows, so does construction acumen and the adoption of materials that are locally available,” says Tshepo.

The construction sector’s exposure to cyber risk also increased due to knowledge workers accessing less secure home networks during the COVID-19 pandemic, requiring companies to increase investment in security infrastructure. Protection against cyber-attacks and protection of intellectual property will be particularly challenging as the industry increases its adoption of disruptive digital technologies. “Technology such as 3D printing and drones, for example, allow for vast areas to be mapped – accurately - which in turn allow for more precise designs. Historical data and new technologies converge in the big data space, catapulting the construction industry into the eye of the cyber-risk storm, making it crucial for the industry to address the risk,” says Tshepo.

Underrated Risk “Climate change seems to be an underrated risk given that large infrastructure projects – power plants, ports, roadways and railways – could be hugely affected by extreme weather events,” says Koketso Shabalala, Senior Broker in Aon South Africa’s Construction, Engineering and Renewable Energy Division. “Extreme weather events such as super storms and veld fires in drought-stricken areas add an additional layer of risk to a project that affects timelines, costs and exacerbates workforce risk. Weather pattern modelling is crucial to navigate ideal timing on projects and mitigating the increased risk that comes with delays,” explains Koketso. Concerns over geopolitical tension as a result of ongoing government-sanctioned lockdowns and the resulting economic hardship, necessitates a review of business continuity planning in the face of political unrest. “Putting processes in place to navigate major supply chain disruptions, safeguard lives and property and reduce the risks to business continuity as far as possible is crucial,” says Koketso.

Facing challenges on the horizon Many industries are entering a “K-shaped” recovery to the pandemic, with different parts of the economy recovering at different rates. “It is important to take stock of how the industry was affected and how processes can be adapted or changed to find a more streamlined approach in future,” says Tshepo. “Central to this, is changing processes, for example, adopting the use of prefabricated items to allow for less people on site in addition to a ‘plug and play’ approach that reduces time spent on site. The pandemic is also likely to affect the type of buildings that are being built, debating whether open-plan offices are still viable and affecting the flow of buildings to allow for social distancing,” Koketso explains. Amid growing global complexity, the convergence of risk factors and increasing integration among coverage lines, participants in the construction industry will need to consider risk in a multidimensional fashion rather than by line of coverage. Leading firms have already adopted this approach and have seen better outcomes as a result. This is where the insights of an expert broker who specialises in the construction sector is invaluable in aiding organisations to combine traditional and more innovative risk mitigation strategies to improve performance and make better decisions. n

Concrete Trends Issue 4 2021

Strategic trends

New strategies for the business of building Some luck, a lot of mitigation and an extremely wide net De Sousa says the initial stages of the pandemic didn’t have the dire impact initially expected as projects were already on their books, but investor sentiment declined rapidly during the hard lockdown which led to a downturn in the company’s order book in the early part of 2021. “As investor confidence has since improved and the different stages of lockdown have eased, we’ve seen a glimmer of hope and recovery with more opportunities on the horizon.” The key to GVK-Siya Zama’s survival over this time has been its hands-on approach. “During the initial lockdown period, we spent our days in online team strategy sessions to mitigate risk, manage costs and keeping our teams involved, motivated and productive.” Investor sentiment has started to shift since Q3 this year and De Sousa says this augurs well for the industry and the country. “We are hoping to see the fruits of this in the next year as Covid gradually loses its grip on the country.”

Trusting public investment

John de Sousa

he succession of businesses closing their doors in the face of the most treacherous conditions in living memory was at once a major loss to our economy and a personal loss to many. The building sector was hard hit, and is faced with the challenge and the opportunity to realise a central role in an economy that is unusually malleable. The tools to build back a better model, fit for the challenges of the fourth industrial revolution include figuring not only why some survived, and other even thrived through this period. While the South African GDP has seen some growth in the last four quarters, the construction industry remains key to expediting the recovery and creating jobs, according to CFO of privately-owned construction company, GVK-Siya Zama, John de Sousa. De Sousa has been at GVK-Siya Zama for more than two decades, playing a pivotal role in the growth of the business and says that, over the past five years, the company has seen annual turnover grow 20% year on year, despite the global pandemic. This was achieved while many of GVK-Siya Zama’s competitors, including several listed companies, went out of business in some of the most treacherous conditions the economy has ever faced.

Concrete Trends Issue 4 2021

Another catalyst to the recovery of the industry will be government infrastructure spend which is critical for job creation and economic recovery. “Government infrastructure spend and the rollout of projects and services to communities remain critical to the wellbeing of our country and its people. Government can jumpstart the economy and create numerous jobs through infrastructure spend. In turn, the construction industry plays a multifaceted role in economic growth through skills transfer, SMME growth and development, and creating local employment in communities where projects are taking place,” explains De Sousa.

Building in technology Today, De Sousa and his executive colleagues lead a modernised construction company with a young, hands-on management team. This approach, coupled with an ethos of integrity and hard work, has contributed to the business’s steady growth trajectory since 2015. The evolution of the company has seen this former painting and renovation contractor join the construction big league with big ticket projects of increased complexity requiring top notch skills and big match temperament. “In the last decade, we’ve grown to become a fully-fledged building contractor and count as one of the biggest privately owned national construction companies in the country. Our step up to the major league, combined with people-centric employment practices has positioned us as a preferred employer who attracts some of the best talent in the industry,” says De Sousa. In conclusion, he says the construction industry remains one of the most inefficient industries, and the company’s focus remains on reducing inefficiencies and subsequently, improving bottom-line. n

Strategic trends

SIKA acquisition reinforces growth sustainablity leadership

ika has signed a definitive agreement to acquire MBCC Group, the former BASF Construction Chemicals, from an affiliate of Lone Star Funds, a global private equity firm, for a consideration of CHF 5.5 billion (EUR 5.2 billion). MBCC Group is a leading supplier in construction chemicals worldwide. The acquisition will complement and broaden Sika’s product and solution offerings in four of five core technologies and seven of eight Sika Target Markets and will further strengthen its geographic footprint. The combined business will be a key accelerator in enabling both Sika’s and MBCC Group’s customers and the construction industry to drive the sustainable transformation further and faster. MBCC Group, headquartered in Mannheim, Germany, is active in the field of construction systems and admixture systems. With approximately 7,500 employees MBCC Group has operations in over 60 countries and more than 130 production facilities. In 2021, the company is expected to generate net sales of CHF 2.9 billion (EUR 2.7 billion). MBCC Group has a world-renowned product portfolio of global and local brands which enjoy a strong reputation for quality and reliability. With its broad and balanced product offering, MBCC Group participates in all phases of the construction life cycle and is a key contributor to the decarbonisation of the construction industry. Thomas Hasler, CEO of Sika says: “Two sustainability champions will join forces. Sika is first in class for sustainable solutions across the entire construction industry, and similarly, sustainability lie at the core of MBCC Group’s business. Together we will reinforce our complementary range of products and services across the entire construction life cycle. With our combined portfolio, we will enable and accelerate the future of sustainable construction for the benefit of customers, employees, shareholders, and coming generations.” Jochen Fabritius, CEO of MBCC Group says: “We have found a perfect partner who shares our core beliefs. Sika is well-known for its entrepreneurial spirit and its profitable growth strategy, including a strong acquisition track record. Our products and competencies will again be at the core of the business. Together with Sika, we are looking forward to exploring new and exciting business opportunities. I would like to thank Lone Star for the tremendous support during the past few years and for helping us to prepare for this next chapter.” The transaction will accelerate Sika’s resilient Growth Strategy 2023 and beyond. Sika will expand its product and

service offering in construction chemicals and industrial adhesives by adding the highly complementary portfolio of MBCC Group and is set to reach sales in excess of CHF 13 billion in 2023. The combination will lead to a very balanced product portfolio with all of Sika’s Target Markets achieving between CHF 1 and 2 billion in sales. Customers will benefit from an enhanced and more efficient distribution network across all construction markets. Sustainability stands at the core of both companies. As such, the acquisition combines two highly motivated and extremely capable global teams that will support a strong sustainability footprint for the future. Today, 70 percent of Sika’s sales is generated by products that have a positive effect on sustainability, whereas more than 35 percent of MBCC Group products are sustainably advanced. Through the combination, Sika is committed to generating 80 percent of its sales from products that positively impact sustainability. The acquisition is subject to regulatory approval. Sika is confident it will obtain all clearances and will actively engage with the authorities. The closing of the acquisition is targeted for the second half of 2022. n

About MBCC Group MBCC Group is one of the most recognised companies in construction chemicals worldwide with sales of approximately CHF 2.9 billion (EUR 2.7 billion) • Enterprise value of CHF 5.5 billion represents a 11.5x EV/pro forma 2022E EBITDA multiple with expected annual synergies of CHF 160 – 180 million bringing the multiple down to 8.5x EV/EBITDA • Transaction is highly complementary across almost all of Sika’s core technologies, applications, and solutions` • Acquisition is accretive to Sika’s earnings per share from the first full year post closing • The combined company will drive the sustainability transformation of the construction industry further and faster • Transaction is subject to regulatory approval, but Sika is confident that all required clearances will be obtained. Closing targeted for the second half of 2022

Concrete Trends Issue 4 2021

Product trends

Two new quick-setting self-levelling floor screeds a.b.e. Construction Chemicals, now part of the Saint-Gobain Group has launched two new versions of its dustless abescreed SLC P self-levelling floor screed to add screeds of varying strengths with different walk-on times and characteristics. abescreed SLC P has over the past seven years won wide acclaim and popularity throughout Sub-Saharan Africa and has even been installed at a major hospital in the Democratic Republic of the Congo. The two new quick-setting self-levelling screeds, abescreed SLC P 15 and SLC P25, offer typical 28-day compressive strengths of 15MPa and 25MPa, with matching flexural strengths of 6MPa and 9MPa, respectively. Walk-on time for abescreed SLC P 15 is about six hours, while SCL P25, can handle pedestrian traffic after only four hours. abescreed SLC P 15 is ideal for vinyl or ceramic tile covering while the stronger SLC P 25 is suitable for surface coatings such as epoxy.

Environmental health benefits Peter Jones, a.b.e.’s National Flooring Sales Manager, says abescreed SLC P has been widely applied for fast track refurbishment and new construction where finishes such as carpets, ceramic tiles, vinyl, wood block, or cork flooring had to be applied quickly. “The product has proved extremely popular to level floors in office buildings, houses, shops, public premises, schools and airports. As it is protein-free and does not harbour bacteria, it is ideal for hospitals and clinics in our current pandemic world. The ‘green’ qualities of abescreed self-levelling screed – among the wide range of dustless a.b.e. products – in enclosed flooring environments are also important for the health and safety of applicators,” Jones states. The abescreed self-levelling range can be trowel-applied for thicknesses of up to 20mm, or pumped for screeds of between 4mm to 20mm. An 8mm average thickness is usually

The abescreed self-levelling range has been widely successful for demanding, fast track projects, including major hospitals

Concrete Trends Issue 4 2021

Product trends

Example of a SLC P pumped-on floor

The abescreed SLC P application

satisfactory on a reasonably level base. Floor coverings can be laid after 12 to 24 hours, depending on the screed’s strength and day temperatures. If pumped, a surface area of about 2 000m2 can be achieved in just a day.

Performance factors of fit-for-purpose screeds “Priming of the floor surfaces with abeprime SLC acrylic primer improves the self-levelling screed’s adhesion to the concrete substrate, reduces substrate absorbency and seals the substrate. Correct surface preparation, as well as mixing and proportioning of the abescreed self-levelling screed, are essential for good results. The correct tools should also be used and a.b.e’s prescribed application method followed,” Jones advises. He says the following factors should be considered when choosing a fit-for-purpose screed: • Slip, abrasion, and impact resistance; • Type of traffic on the floor; • Type of flooring to be used on top of the screed; • Levels and flatness; • Appearance and maintenance; • Drying out of moisture in the screed; and • Location of the floor’s movement joints. Since its launch seven years ago, abescreed self-levelling screed has been used at several hospitals such as the Nelson Mandela’s Children’s Hospital in Johannesburg, 2 Military and Karl Bremer Hospitals in Cape Town, as well as hospitals at Vredenburg, De Aar, Newcastle, and Polokwane. The screed was also specified for the Gutsche Property Ignite Gym in Port Elizabeth, Supa Quick Fitment Centre in the Western Cape, as well as a Community Centre Upliftment Project in the Western Cape. n

The SLC P screed is ideal for epoxy surfaces.

Concrete Trends Issue 4 2021

Global trends

Illuminating South Africa’s global opportunities An exquisite example of technical triumph and creative innovation is a highlight of the new JW Marriot

Grand opening of Charlotte, North Carolina’s first upscale Marriott illuminated by a statement chandelier by leading South African lighting house, willowlamp

he much-awaited first JW Marriott in Charlotte, North Carolina celebrated its grand opening on 18 August 2021. The upscale hotel is described as an urban luxury retreat, and boasts an impressive rooftop bar and pool, oyster bar, Spa by JW, an authentic restaurant, and luxurious wellappointed rooms. However, there is one standout feature that truly lights up the hotel – a strikingly exquisite chandelier adorns the welcome lobby. This custom chandelier is monumental; the one-of-a-kind piece requires an impressive 26 cubic meters of hanging space and weighs over a tonne. Though it now hangs magnificently over a curving staircase in the hotel’s lobby area, it originated on the other side of the Atlantic! This exquisite lighting piece journeyed all the way from Cape Town, where it was created by leading South African-based lighting company, willowlamp to take its place as the talking point of this leading hotel. willowlamp’s award-winning founder and Creative Director Adam Hoets was commissioned by Fabiola Troncoso, an Associate at Chicago’s Simeone Deary Design Group, on behalf of Marriott International in 2018. This was not Hoets’s first commission from the Simeone Deary Design Group – in 2014, the US design firm commissioned willowlamp’s Flower of Life chandeliers for the Hotel Allegro in Chicago. For this most recent project, Hoets initially conceptualised two proposals for this monumental lighting piece, before settling on the way forward. Speaking of the final creative direction, he states: “The piece takes its inspiration from the original version of our very first Mandala design, which we did for Liwa Suites in the UAE, which was commissioned by Jan Lewis of Design Union. We have reconceptualised this piece and adapted it to suit the JW Marriot space.” The resulting willowlamp has impressive distinguishing

Concrete Trends Issue 4 2021

features, that were not without their challenges to achieve. It is like all other willowlamps in that it is composed of cascading tiers of metallic ball chain. But unlike its Mandala predecessor it is not circular, but rather takes the form of a long, narrow ellipse. It is irreverently described by Hoets as “sort of a ‘squashed’ Mandala!”. This vertical flattening presented all-new design challenges for Hoets. It was not just a matter of rotating the same shapes to form a circular pattern – the design required complex creative and technical solutions to bring it to life. For example, “the chain lengths could not just be repeated shapes, they had to all be worked out to fit the stretched proportions, which was much more difficult.” To further complicate matters, the chandelier has upper and lower tiers of chain and was almost too big to manufacture on willowlamp’s premises! The extreme size and weight of the piece also required a creative approach and several design innovations to ensure it could take its place in this flagship hotel. The extruded shapes made up of chain curtains had to be broken up into separate panels. Each panel was then individually mounted to a ceiling frame and fitted together like a jigsaw puzzle. Hoets was forced to approach the design in this way because “it was the only way to install a piece such as this, because the combined weight is one tonne!” Now successfully installed, Charlotte’s new JW Marriott basks in the glow of the piece’s 31 LED lamps. These hang on suspended cables that are hidden within each of the extruded geometrical chain curtain shapes. Which means that the newly opened upscale hotel is illuminated by an exquisite example of technical triumph and creative innovation. For more information on willowlamp see www.willowlamp.com. n

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CONCRETE TRENDS 2021 ISSUE 4

Articles inside

Product trends Speed for screed Global trends

The new road to outcomes and performance

Suspended acceleration – precast slabs

Association trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Acquisitions driven by sustainability

The right mix of concrete for affordable housing

Reduce water and add a step to sustainable concrete

Cement paves the way to a brighter future

Cover Story